Checked valve clearance last night with feeler gauges. 2006 model with 13K miles, I've had it for a little over a year and picked up with 11.5K miles. Don't know if valves have ever been checked or adjusted before. Results:

Lt Ex: between .076 & .102 mm
Rt Ex: 0.15 mm (tight fit)

Lt In: 0.15 mm (tight fit)
Rt In: 0.15 mm

Specs: Inlet 0.10 - 0.20 mm. Exhaust 0.15 - 0.25 mm.

Questions: Is it typical on these for the exhaust to be out of spec before intake? Is there anything I should be especially concerned with on the left exhaust being so far out of spec? Plan to pull the exhaust shims out tonight and replace appropriately.

Thanks.

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If it were my bike ...
Concern? Nah. I'd just adjust and ride it. To me its not THAT far out. If it were dangerously out of spec the exhaust valve wouldn't be allowed to close all the way, letting the exhaust gasses ignite, and you'd be backfiring.

Where can I find the CHEAPEST crashbars for my '02? I don't need anything fancy, if anything I just want something half-assed so I can mount my GoPro camera to it for cool shots. Is it possible to have them made?

Where can I find the CHEAPEST crashbars for my '02? I don't need anything fancy, if anything I just want something half-assed so I can mount my GoPro camera to it for cool shots. Is it possible to have them made?

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Mounting any video equipment to a motorcycle just ensures you'll crash. Cheapest is to sell the GoPro and go ride!

Well, Since I got the IMS tank, I was immediately unsatisfied with the less than perfect welds, molding, imperfections, etc. I liked the idea of the extra fuel and the protection it provided for the the radiator but it was UGLY!
All the info was, "Nope, can't paint an IMS tank, paint won't stick, stickers won't even stick." Wasn't sure why so I did some research. Most plastic tanks "breathe" hydrocarbons that don't allow for painting and such. OK, how about sealing the tank. Lots of sealers out there but they all say won't work with Polyethylene, Hmm. What is the IMS tank made of anyway? Yep. Polyethylene. XLPE, to be exact, cross linked polyethylene. Caswell has a nice looking 2 part epoxy sealer, oops. Won't stick to Polyethylene.
I finally came across a sealer that the manufacturer wasn't sue if it would work or not but thought it would. I found some blogs that some guys had used it and it worked great but I didn't know if their tanks were XLPE.
Long story short (too late) I ordered some and after a lengthy prep process I sloshed it around and let it cure. Seems to have dried to a flexible, strong bond, time will tell.
IMS tank is not ugly anymore! I have a bit of wet sanding the clear and some polishing to do but that is going to wait a month or so to see if she holds up.

so.... how come the KLR is so popular and so many people rave about it?

It's a bit slow on the road and a bit slow off the road... is it cos it's cheap or what???

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Yes it's cheap to buy, cheap to own, and cheap to rebuild if/when it needs it .. aftermarket parts are available anywhere in the world too, usually for not an insane amount of money ..

It does everything well and nothing exceptionally well .. it's the Volkswagon of the motorcycle world, convertible into a dune buggy, truck, jeep, daily commuter, or anything else you want it to be including a sporty-ish world-touring mile-chomping machine .. and it holds a bunch of gas to get you there and back again at 48-52 mpg ..

Most importantly, it's a fun bike to ride .. not to much power such as to make it a pain in the ass .. and not so little power that you can't climb through, around, over, under, or between most stuff .. It'll go anywhere and everywhere and if you're smart you're not in a hurry anyway ..

....sums it up pretty well. I have 2, one set up for my daily commute and one for the trails (but still very road worthy) it seems to go wherever I point it without missing a beat. I love my KLR's. I think I need a sticker that says that.

....sums it up pretty well. I have 2, one set up for my daily commute and one for the trails (but still very road worthy) it seems to go wherever I point it without missing a beat. I love my KLR's. I think I need a sticker that says that.